Irradiation devices with laser diode arrays for additively manufacturing three-dimensional objects

Abstract

An irradiation device for additively manufacturing three-dimensional objects may include a beam generation device that includes a plurality of laser diode arrays. Respective ones of the plurality of laser diode arrays may include a plurality of diode emitters respectively configured to emit an energy beam. The plurality of laser diode arrays may be longitudinally offset relative to one another, and the plurality of laser diode arrays may be laterally offset relative to one another.

What is claimed is: 
     
         1 . An irradiation device for additively manufacturing three-dimensional objects, the irradiation device comprising:
 a beam generation device comprising a plurality of laser diode arrays, wherein respective ones of the plurality of laser diode arrays comprise a plurality of diode emitters respectively configured to emit an energy beam;   wherein the plurality of laser diode arrays are longitudinally offset relative to one another; and   wherein the plurality of laser diode arrays are laterally offset relative to one another.   
     
     
         2 . The irradiation device of  claim 1 , wherein the plurality of laser diode arrays are longitudinally offset relative to one another by an array offset distance determined relative to an optical axis of the respective ones of the plurality of laser diode arrays. 
     
     
         3 . The irradiation device of  claim 1 , wherein the plurality of laser diode arrays respectively emit a plurality of energy beams, respective ones of the plurality of energy beams emitted from corresponding ones of the plurality of diode emitters;
 wherein the plurality of energy beams provide a corresponding plurality of beam spots incident upon a build array defined by a powder bed disposed below the irradiation device, the plurality of beam spots arranged in a pattern or sequence such that beams spots that become incident upon laterally adjacent build points of the build array are longitudinally offset from one another.   
     
     
         4 . The irradiation device of  claim 3 , wherein at least some beams spots are longitudinally offset from one another in an alternating pattern or sequence. 
     
     
         5 . The irradiation device of  claim 3 , wherein plurality of energy beams provide a linear scan field comprising a first plurality of beam spots laterally spaced apart from one another followed by a second plurality of beam spots laterally spaced apart from one another;
 wherein the first plurality of beam spots and the second plurality of beam spots are longitudinally offset from one another with reference to a longitudinal axis of the build array, and wherein the first plurality of beam spots and the second plurality of beam spots are laterally offset from one another with reference to a transverse axis of the build array.   
     
     
         6 . The irradiation device of  claim 3 , wherein a first one of the plurality of laser diode arrays is configured to emit a first plurality of energy beams, and a second one of the plurality of laser diode arrays is configured to emit a second plurality of energy beams, wherein respective ones of the first plurality of energy beams are laterally offset from respective ones of the second plurality of energy beams by a beam offset distance determined with reference to a transverse axis of the build array. 
     
     
         7 . The irradiation device of  claim 6 , wherein the first plurality of energy beams provide a first plurality of beam spots that become incident upon and propagate across the build array as a first row and wherein the second plurality of energy beams provide a second plurality of beam spots that become incident upon and propagate across the build array as a second row. 
     
     
         8 . The irradiation device of  claim 1 , wherein the plurality of laser diode arrays are configured to emit energy beams that have a wavelength in the ultraviolet spectrum, the visible spectrum, the near-infrared spectrum, or the infrared spectrum. 
     
     
         9 . The irradiation device of  claim 1 , comprising:
 a beam conditioning assembly be disposed downstream from the beam generation device, the beam conditioning assembly comprising one or more lenses, the one or more lenses comprising a fast-axis collimating lens and/or a slow-axis collimating lens.   
     
     
         10 . The irradiation device of  claim 9 , wherein the beam conditioning assembly comprises a beam homogenizer. 
     
     
         11 . The irradiation device of  claim 1 , comprising:
 a beam focusing assembly disposed downstream from the beam conditioning assembly, the beam focusing assembly comprising one or more focusing lenses.   
     
     
         12 . The irradiation device of  claim 1 , comprising:
 a positioning system, wherein the irradiation device is mounted to the positioning system, wherein the positioning system is configured to move the irradiation device.   
     
     
         13 . The irradiation device of  claim 1 , comprising:
 an irradiation carriage, wherein the plurality of laser diode arrays are coupled to the irradiation carriage; and   one or more actuators, wherein a respective one of the one or more actuators is configured to adjust a position of at least one of the plurality of laser diode arrays coupled to the irradiation carriage.   
     
     
         14 . The irradiation device of  claim 1 , wherein the one or more actuators are respectively configured to provide a lateral positional adjustment and/or a longitudinal positional adjustment of the at least one of the plurality of laser diode arrays. 
     
     
         15 . The irradiation device of  claim 1 , comprising:
 an irradiation carriage, wherein the plurality of laser diode arrays are coupled to the irradiation carriage, wherein at least some of the plurality of laser diode arrays are arranged laterally adjacent to one another.   
     
     
         16 . The irradiation device of  claim 1 , comprising:
 a plurality of diode array groups, the plurality of diode array groups respectively comprising at least some of the plurality of laser diode arrays;   wherein the plurality of diode array groups are arranged longitudinally adjacent to one another and separated from one another by a group separation distance;   wherein respective ones of the plurality diode arrays corresponding to the respective ones of the plurality of laser diode arrays belonging to a respective one of the plurality of diode array groups are longitudinally adjacent to one another and separated from one another by a row separation distance, wherein the group separation distance is larger than the row separation distance.   
     
     
         17 . The irradiation device of  claim 16 , comprising:
 a plurality of diode array sets, the plurality of diode array sets respectively comprising at least some of the plurality of diode array groups;   wherein the plurality of diode array sets are arranged longitudinally adjacent to one another and separated from one another by a set separation distance;   wherein the set separation distance is larger than the group separation distance.   
     
     
         18 . The irradiation device of  claim 17 , comprising:
 wherein the plurality of diode array sets comprises a first diode array set and a second diode array set, wherein a corresponding one of the plurality of laser diode arrays belonging to the first diode array set is configured to exhibit one or more irradiation parameters that differs from a corresponding one of the plurality of laser diode arrays belonging to the second diode array set, the one or more irradiation parameters comprising: beam power, beam intensity, intensity profile, wavelength, spot size, and/or spot shape.